2

“AIR COOLER” Heat ExchangerGeneral Assembly view

Structure

Stationary Header

Floating Header

Plug

Tubes

Electric motor

Fan

Conveyor

Inlet

Outlet

Scaffold

3

“AIR COOLER” Heat Exchanger

Tube Bundle DetailsVapor Inlet

Condensate Outlet

Stationary Header

Fin Tubes

Floating Header

Plug

4

“AIR COOLER” Heat Exchanger

Tube Assembly and Plug Detail

Stationary Header

Fin Tubes

Plug

Gasket

Inlet

Grooves for expansion

5

“AIR COOLER” Heat Exchanger

Maintenance Activity Cases Summary

1. Leakage from Header Plugs

2. Leakage from Tubes

1.1. On Line leak elimination [Temporary solution]

2.1. Leak elimination from expanded area

2.2. Leak elimination from broken tube

2.3. On line Leak elimination from broken tube

[Temporary solution, Bottom & Top row only]

6

Do Not Start The Job Without a Safety Plan

7

“AIR COOLER” Heat Exchanger1. Leakage from Header Plugs

1.1. On Line leak elimination [Temporary solution]

Drill blind hole and thread the leaking Plug on situ

Assembly the special cap device with gasket and screw it in until the leak stops

This is a Maintenance Innovation made by IZ

Leaking Plug

Screw in the threaded stud

Inlet Header

Fin Tubes

Replace gasket & Plug later in Shutdown

Special device

Leak

Additional Gasket

8

“AIR COOLER” Heat Exchanger2. Leakage from Tubes: 2.1. Leak elimination from Tube Expanded Area

Shutdown, isolate & drain the equipment

Stationary Header

Fin Tube

Blind Stationary Header Inlet & Outlet

Install Pressure Gauge

Connect water pump

Fill system by water

Locate leaks from outside

Raise the pressure

Open Plugs at leak position

Remove gasket

Plug

Water Pump

PG

Leak

See continuation

Discharge water

9

“AIR COOLER” Heat Exchanger2. Leakage from Tubes: Insert Expander tool, expand the tube up

to the established torque

Stationary Header

Fin Tube

Remove expander tool

Reinstall new gasket and plug

Fill the system by water

Re-check leaks from outside [No more leak]

Raise the pressure

Discharge water

Remove PG & water pump

Plug

Water Pump

PG

Leak

Remove In-Out Blinds and tight flange bolts

2.1. Leak elimination from Tube Expanded Area

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“AIR COOLER” Heat Exchanger2. Leakage from Tubes:

Stationary Header

Fin Tube

Plug

Water Pump

Leak

Shutdown, isolate & drain the equipment

Blind Stationary Header Inlet & Outlet

Install Pressure Gauge

Connect water pump

Fill system by water

Locate leaks from outside

Raise the pressure

Open Plugs at leak position both sides And remove gasket

Plug the leaking tube [both sides]

Fill in water again

Raise pressure & check sealing

Drain water, remove PG & pump

Remove in-out blinds, tight bolts

Remove field blinds

2.2. Leak elimination from broken Tube

Drain water

Reinstall gasket & plugs [Both sides]

PG

11

“AIR COOLER” Heat Exchanger2.3. On line Leak elimination from broken tube : [Temporary solution]

[Bottom & Top row only]

Drain Valve

Section “B-B” Section “C-C”

Leak

B

B

C

C

Special Device

See continuation

12

“AIR COOLER” Heat Exchanger2.3. On line Leak elimination:

Steam

Condensate

DEVICE INSTALLATION METHOD

Leak

from broken tube : [Temporary solution]

[Bottom & Top row only]Stop the fan set only

Remove fins at leaking areaInstall the upper half body with gasket

Install the lower half body with the drain open

Tight the body bolts

Install packing and gland at left side and tight bolts

Install packing and gland at right side and tight bolts

Close the drain

Erect scaffold below fan

13

“AIR COOLER” Heat Exchanger

Handover & Final House Keeping

Close Work permit

Remove tools and equipment

Clean and wash the area

Remove scaffold before El. Fan start-up

By Maintenance